Bulk Handling Technologies is keeping safety at the forefront with several solutions that help isolate bulk materials.
When working downstream of bulk material, staff are at risk of potentially uncontrolled material discharge. This can include large masses of material or smaller, dislodged pieces falling unexpectedly.
Even in bins that appear mostly empty, residual material poses a hazard.
“Even if a bin looks 99 per cent empty, a dislodged rock could still fall and cause serious injury. Isolation gates help prevent these incidents by securing the bulk mass and stopping any loose material from falling,” Bulk Handling Technologies (BHT) engineering manager Paul Ingleson said.
“If you’ve got no way of isolating your stored material, whether it’s 20 tonnes or 1000 tonnes, you’re faced with significant downtime trying to remove that bulk material just to safely access the equipment downstream.
“By having a robust isolation system, maintenance teams can access equipment without emptying the storage, allowing them to complete their work safely and get the system back up and running much quicker.”
Isolation gates can handle those loads and prevent any risk of falling material. Beyond full-bin isolation, there are also scenarios where isolation gates prevent material from being inadvertently fed down chutes.
“You might not necessarily have stored material, but there could be operating equipment above. Having an isolation gate in place ensures material isn’t mistakenly fed onto personnel working below,” Ingleson said.
Selecting isolation gates
Choosing the right bin isolation gate requires careful consideration of the material properties and operating conditions. Factors such as particle size, weight, and moisture content all influence gate performance.
“Do you need the gate to operate while the material is flowing? Can it close when everything is jammed up? Will it be required to open when the bin is completely full? These are critical questions to address,” Ingleson said. “There’s no point in installing a gate that lacks the necessary energy to open once the storage is full.”
Several design elements contribute to the reliability and lifespan of bin isolation gates. Features such as wear-resistant digging horns, maintenance locking pins, and dual overlapping plates are crucial for ensuring long-term functionality.
“Bin isolation gates aren’t continually operating; they may stay open for months at a time,” Ingleson said. “During that period, thousands of tonnes of material pass by, leading to build-up that can harden internally. Digging horns are essential for clearing out any hardened material when the gate needs to be closed. Without them, operators might struggle to fully close the gate.”
Mechanical locking pins provide an extra layer of safety. These pins allow personnel to physically secure the gate with a personal danger tag. If something goes wrong and the gate tries to open while workers are underneath, the pins stop the gate from moving.
Dual overlapping plates also enhance gate effectiveness. Ingleson said when dealing with large, lumpy material, you can’t rely on crushing it between two plates to achieve isolation.
“Instead, overlapping plates pass by each other, allowing the gate to close even in the presence of hard lumps. This ensures secure isolation even through bulk material with a large percentage of lumps.”
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Wear liner packages further contribute to gate longevity by adapting to different material types.
“Depending on the application, we can customise the wear liner thickness to achieve optimal durability,” Ingleson said. “Some materials require thicker liners to extend their lifespan, with replacement intervals of five years or longer often required.”
Expanding beyond iron ore
Bulk Handling Technologies’ bin isolation gates were originally developed for the iron ore sector in Western Australia.
Over time, the design has evolved to accommodate a broader range of industries and materials, including lithium and gold mining.
“We’ve taken that heavy-duty iron ore design and successfully adapted it for smaller applications,” Ingleson said.
“While some industries may not have the same extreme conditions as iron ore mining, they still benefit from the durability and performance features developed for that sector.”
One key advancement has been the shift from hydraulic to electric actuation.
The original gates relied on high-force hydraulics, but Bulk Handling Technologies has now developed electrically actuated gates using direct electric actuators or rack-and-pinion drives.
Applications requiring lower forces may not require the added expense of a hydraulic power pack. Instead, they operate via a simple electric motor, making them easier to integrate into various systems.
Customising for specific applications
BHT’s hydraulic bin isolation gates offer extensive customisation options.
Ingleson said each gate is designed to fit a specific application because no two bins or chutes are identical.
“We manufacture to order, allowing us to modify the gate’s structural and mechanical design to fit space constraints and operational requirements,” he said.
“Some customers need the ability to fill the bin with the gate closed, while others don’t. Understanding these requirements ensures the gate performs as intended.”
Beyond standard isolation functions, some gates are used to direct material flow. Some customers use isolation gates to control feed direction, closing one gate to divert material into another stream.
“We can customise designs to accommodate these requirements and even integrate chute work where necessary,” Ingleson said.
BHT’s bin isolation gates are no longer just for large iron ore operations.
The company’s ability to adapt and customise designs for a variety of industries ensures safe, efficient bulk handling across multiple applications.
“The same core features that made our iron ore gates successful now benefit a wide range of materials and industries,” Ingleson said.
“By continuously refining our designs and offering tailored solutions, we ensure that operators have the best possible isolation systems for their unique needs.
